THE DEFINITIVE GUIDE TO

PRODUCTIVITY IN
THE JOB SHOP
 TABLE OF CONTENTS

01: INTRODUCTION
Page 3

02: COMMON CHALLENGES

Pages 4 - 5
• Technology
• Methods
• Staff

03: SOLUTIONS
Pages 6 - 18
• Solution #1 - Eliminate Manual Programming
• Solution #2 - Automate CAD Programming
• Solution #3 - Simplify Your Workflow
• Solution #4 - Use Simulation
• Solution #5 - Increase Machine Utilization with Fixturing
• Solution #6 - Increase Machine Utilization with Pallets and Robots
• Solution #7 - Automate Setup and Inspection
• Solution #8 - Utilize Additive Manufacturing

04: CONCLUSION
Page 19

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 INTRODUCTION
Due to smaller lots sizes and the demand for shorter leads times, creating efficiencies is critical for
manufacturing job shops. While many job shops look for a single solution that will give them a competitive
edge, the reality is that there is no one magic bullet to gain that productivity advantage.

Instead, the key to boosting efficiency is to examine the complete manufacturing process end-to-end and
make many incremental gains each step of the way. This comprehensive guide will give you a broad set of
techniques to help increase the productivity of your job shop.

3 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 COMMON CHALLENGES
When it comes to productivity, job shops face many of the same issues around technology, methods, and staff.
Understanding these challenges is the first step towards creating more efficient workflows, more consistent
results, and increased productivity.

4 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 COMMON CHALLENGES
Technology
All too often, engineers think about technology
in relation to one or two aspects of their process.
But it applies to each piece of the workflow.
And it evolves continually.
Methods
To gain a competitive advantage as demands are
increasing, commit to experimentation. Try new
methods with the understanding that not all of
them will produce the desired advantage.

CNC MACHINE TOOLS The biggest challenge is often mindset. Many job
shops get into a routine and avoid new methods for
New features and performance enhancements
fear of missing ship dates on parts, scrapping parts,
include increased spindle power and improved
or slowing down the rate of throughput in the short
drives for accuracy.
term. While this might be advantageous at
CNC CONTROLLERS the time, these shops are missing out on a long-
term advantage.
Updates include faster processors and
increased memory.

CAD/CAM SOFTWARE
Ongoing development means there are always
Staff
new features and functions.
You need highly skilled employees, and finding the
right people can be a challenge. Once you do, you
CUTTING TOOLS
need the time to train them on existing tools while
Providers are improving coatings, helix angles
somehow finding time to ramp them up on new
and insert designs.
technologies. Many shops run at a fast pace, so
high-performing employees can find their creativity
WORK-HOLDING AND MACHINE-LOADING
hampered by a huge workload.
These are evolving for shorter non-milling
times between parts.

5 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 SOLUTIONS
This guide will help you adopt changes that improve productivity. We focus on solutions that support the following
strategies, as they tend to produce the greatest gains:

MANUFACTURE MAXIMIZE THE MAXIMIZE THE

COMPLEX PARTS
The more complicated
the job, the higher the
profit margin potential.
UTILIZATION OF EACH CAPABILITIES OF
MACHINE EACH MACHINE
As they say, “if the You may have access
spindle isn’t turning, to features that you are
you aren’t earning.” not using.

6 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 SOLUTION #1
Eliminate Manual FEWER ERRORS
With manual programming, there may be simple

Programming
typographical errors and incorrect calculations.
Many trigonometric math functions are used
when programming parts manually, and if the
Adopt computer-aided manufacturing (CAM) math is off, the program is incorrect.
software if you haven’t already. You will find
CAM software uses its own algorithms to
that you can bid more competitively on more
produce error-free CNC code.
complicated parts (with higher profit margins).
QUICKER MODIFICATIONS
Benefits of CAM vs. Part-changes and revisions call for updates
to existing CNC programs. A manual process
Manual Programming is time consuming: find what needs to be
changed, make the correction, and perform
LESS DOWNTIME another dry run to check it.
Often manual programming is done
CAM software enables fast part modifications.
sequentially. The part is programmed at the
In many cases, the toolpath automatically
machine controller, it is proven in a dry run,
updates with part revisions from engineering
and finally stock material is machined.
change orders.
This method often leads to a significant
amount of downtime where the CNC machine
is not being used for production. With CAM
software, parts can be programmed ahead of
time and are available when the machine is
ready for the new parts.

7 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 SOLUTION #1 (continued)
Eliminate Manual
Programming
Benefits of CAM vs.
Manual Programming
FASTER PROGRAMMING OF COMPLEX PARTS
As parts get more complicated, the amount
of time it takes to manually program them
grows exponentially.
With CAM software, you can program more
complex shapes using a lot of the same
programming methods and strategies you use
for simple parts. It doesn’t take much longer.
8 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP
HIGH FEED RATES
Often in manual programming, the cutter load
varies based on the geometry. Operators must
run the machine at a slower speed to account
for variances. This typically happens in corner
regions where the tool engagement increases.
With CAM software, you can control the
engagement angle of the tool—typically
during roughing operations. You can maintain
a high feed-rate since there is no danger of
overloading the tool.
BETTER PROGRAMMING STRATEGIES,
COLLISION CHECKING
With manual programming, you cannot take
advantage of the newest strategies that allow
for constant scallops, toolpath morphing,
spiral, or radial cutter strategies.
With CAM, you can keep track of the stock
condition between operations. You get
advanced collision checking that is not
possible with manual programming.
 SOLUTION #1 (continued)
Eliminate Manual
Programming
Benefits of CAM vs.
Manual Programming
REDUCED STAFFING NEEDS
With manual programming, absences
mean downtime.

With CAM software, one person can program

for dozens of different machines and
controllers, and process the data for multiple
machines. Also, it doesn’t take long to bring
a CAM-trained engineer up to speed on your
unique machine/controller combination.

9 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 SOLUTION #2
Automate CAD CREATE TEMPLATES
Set up a template for a sequence of operations

Programming
CAM programming enables you to impart your
knowledge into the software so that it can
automatically make intelligent decisions based on
your input. The results can be far reaching. Use
these techniques to simplify your programming
process and grow your productivity.
Programming Automation
Techniques
AUTOMATE TOOL SELECTION, TOOL PARAMETERS
A tool library can be used to help automate
and simplify the tool selection process as
well as the tool parameters. Tool libraries
can often include important values such as
speeds and feeds for various materials and
cutters. Selecting the tool and material will
automatically populate parameters necessary
for the tool and material combination.
you will repeat often, and minimize redundant
programming. For example, on similar sized
parts, you may always start milling or turning
with the same four tools and operations. Instead
of adding the same four programs every time,
you can create a template for those operations.
This method works especially well on similar
parts or families of parts.
CUT AND PASTE PARAMETERS
Often job shops work on parts that are of
similar shapes and sizes. You can apply the
parameters from one completed part to
another new part. If the programming of
one part was deemed to be very efficient,
for example, you could simply copy those
parameters to a new, similar part, and calculate
the new result.
Just cut and paste, or drag parameters from
the completed part to the new part.

Tool libraries only show tools used for a

specific operation. For example, if you choose
a chamfer operation, the tool library will only
show chamfer tools.

10 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 SOLUTION #2 (continued)
Automate CAD AUTOMATE RE-MACHINING
It’s hard to keep track of where stock has been

Programming removed and where stock remains. This is

Programming Automation
Techniques
AUTOMATE FEATURE CALCULATIONS
Specify a key feature of a part and apply
a complete strategy to that feature. The
parameters will be automatically calculated.
Best of all, if you change a size or shape,
operations are automatically updated.
especially true when larger cutters are used for
most of the machining process, but there are
still smaller corner radii that contain excess
material that needs to be removed.
CAM software can automatically locate
material remaining to be machined, and
re-machine it during roughing or finishing
operations. Automated re-machining allows
the user to program for residual material
quickly and efficiently, and with fewer errors.

SET PARAMETERS FAST USING

FEATURE RECOGNITION
CAM software can analyze a model and list
every feature it finds. It determines the
operations for each feature, then orders them
for maximal machining efficiency based on
their properties. For example, an open pocket
may be machined with a different strategy
than a closed pocket, or shallow bosses may be
milled differently than tall ones.

11 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 SOLUTION #3
Simplify Your
Workflow
While automation breaks down each step of a
workflow, simplification involves shortening the
number of steps. For example, if your current
workflow takes ten steps to go from design to
finished part, simplification would reduce the
number of steps required. In general, automation
goes hand and hand with simplification.
How to Simplify Your
Workflow
INTEGRATE CAM AND CAD SOLUTIONS
With integration, programming and design
teams can utilize the same software. This
eliminates the steps required for exporting
files and loading them into separate software.
It also removes the need to translate part
geometry, which can cause problems at import.
Integration also gives programmers access to
CAD tools, to make any necessary edits to the
geometry for manufacturing.
12 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP
UTILIZE ANYCAD
Many job shops get their CAD data from
a variety of sources, in many different CAD
formats. When working with outside
data, keeping track of changes and data
can be tricky.
With AnyCAD, you do not translate third party
data, but rather load the part directly into your
workspace. Changes to the original model will
show up in your model, and CAM programs will
update as necessary. This not only reduces
mistakes, but also simplifies the workflow
when changes are necessary.
IMPROVE COLLABORATION
Any time you stop a manufacturing process
to get new information, time is added to your
workflow. Ongoing, close collaboration with
colleagues and clients can help you identify
issues earlier, minimize interruptions, and
speed up time to completion.
STANDARDIZE CNC PROCESSES
Eliminate the clutter that comes with tooling
every machine and part separately. It wastes
time and introduces unnecessary equipment
into the workflow.
 SOLUTION #4
Use Simulation
To increase productivity, use simulation within CAM
software before machining. Simulation provides
you with a digital representation of the milling
or turning process, including the stock material
removal, before machining the parts. Because you
avoid errors, there is less downtime.
Benefits of Simulation
AVOID DRY RUNS
Digitally simulate parts to see whether you
have a quality toolpath, and to find errors.
This is better than a dry run. The simulation
can show the stock before a milling or turning
operation, as well as the condition of the
material after each successive operation.
By including clamps, vises, and fixtures in the
CAD/CAM environment, the simulation will
show if there are any collisions between the
tool and the fixturing. This is something often
difficult to see when performing a dry run.
13 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP
CATCH ERRORS EARLY
Without simulation, errors are sometimes
found while running your mill or lathe. This can
cause considerable downtime. With simulation,
errors within the toolpath will show up on
the simulated model. Boost efficiency by
correcting errors before the part is loaded into
the machine.
VIEW REMAINING STOCK
Assess what stock remains after each
operation, and verify that the part is finished
after the last operation.
USE SHORTER CUTTERS
One key way to increase efficiency is to run
with the shortest cutters possible. Short
cutters deflect less, and can usually be run
at a faster feed rate. Utilizing advanced CAM
software, you can calculate for the tool and
holder to avoid collisions. Verifying there
are no collisions with the tool holder during
simulation allows for utilizing shorter tools
with faster feed rates.
 SOLUTION #4 (continued)
Use Simulation
Benefits of Simulation
PREVENTS MACHINE CRASHES
Multi-axis and multi-tasking machines, such as 4
and 5-axis mills, turn-mills or Swiss lathes, add
an extra layer of complexity to the machining
process. Not only are these machines typically
more expensive, they are easier to damage.

Completely simulating your multi-axis

toolpaths can save significant downtime from
an inadvertent machine crash. Additionally,
simulation can be used to help find rotation
angles for 3+2 axis machining where tool and
tool holder clearance are important. Simulating
multi-tasking machines can verify the machine’s
position during synchronization, and ensure your
machine runs collision-free.

ENABLES SAFE OVERNIGHT RUNS

Simulate your toolpaths until you gain the
confidence to run your machine unattended.
This provides a significant boost in efficiency
because you capture those hours.

It also frees up your workforce to start

programming the next parts while a machine is
running, or run multiple machines at once.

14 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 SOLUTION #5
Increase Machine
Utilization
with Fixturing
One of the best ways to get the most out of your
CNC mill is to fill it up as much as possible when
milling. If you can fit two parts in at the same
time instead of one, you reduce the total number
of setups and reduce the downtime caused by
swapping parts.
Fixturing Methods
INSTALL MULTIPLE VISES
Clamp down multiple parts and machine them
in one run. You can also take advantage of
vises that hold two parts at one time.
INSTALL A TOMBSTONE
Installing a tombstone is a more advanced way
of milling multiple parts at one time in your
mill. A tombstone is basically a multi-sided
fixture that rotates, and you can mount parts
to mill onto each side. The tombstone will
rotate into position and the parts on that side
can be milled.
15 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP
MAKE A MULTI-ORIENTATION FIXTURE
Many parts require milling from multiple
angles. These can often be done efficiently
on multi-axis machines, like a 5-axis milling
machine. If you don’t own this type of mill,
you can still mill all the sides through multiple
operations.
In this case, make a fixture that can hold the
part for each orientation of milling. That way
parts can be moved from one station of the
fixture to the next, then simply run the same
program again. This is generally faster than
setting up the machine for each orientation
and running the parts separately.
USE A SELF-CENTERING FIXTURE
Place a self-centering vise on the table and
zero it to the center once. Provided every part
has its origin in the center, you don’t need to
re-zero the vise.
Other vises have attachments that can be
added. If the attachment utilizes locating
pins or other locating hardware, it reduces
the downtime required from constantly
re-zeroing the part.
 SOLUTION #6
Increase Machine
Utilization with
Pallets and Robots
Boost utilization with quick-change pallets and
automatic loading. Many CNC mills are able to swap
out pallets that are already aligned— in just a couple
minutes. With no need to set up individual parts,
there’s less downtime.
PALLETS WITH SINGLE MACHINES
Mill one part while setting up the next one
to mill on a pallet. This allows for quick
swapping out of pallets. Location points on
the pallets allow for setting up and utilizing
work offsets easily.
16 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP
PALLETS WITH MULTIPLE MACHINES
You can optimize the machining based on the
hardware as well. For example, while utilizing a
pallet you can:
• Rough the part on one machine and finish
on another to optimize the individual milling
machine strengths, if one is better suited for
a task than another.
• Machine on less expensive 3-axis mills and
send the pallet to a more expensive 5-axis
machine only when necessary, instead of
having it mounted there for the whole part run.
• Run on the first available machine, if waiting
in a queue.
 SOLUTION #7
Automate Setup IN PROCESS VERIFICATION
Verify if the tolerance of a machined feature

and Inspection
Many milling machines utilize probes for part setup
prior to machining. Use these probes to perform
time-saving operations.
conforms to specification during the machining
process. It is better to stop a run part way
through to make a correction because of a
critical dimension, than to waste time running
the whole part, only to find out at the end it
was out of specification.

SET PART ORIGIN

Probes can verify a stock block size and set the
origin based on the probed features. If a part is
not aligned perfectly, it can be adjusted based
on the deviation from the inspection results.

Probes can often find the center of a hole or

boss much faster than can be done manually
with a dial indicator. Use them to reduce
downtime and increase safety by minimizing
human intervention.

17 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 SOLUTION #8
Utilize Additive
Manufacturing
Additive manufacturing can complement CNC
milling in many ways. It can be used to manufacture
soft jaws or other fixture items to hold the part for
secondary machining operations.

3D-printing of metals can be used to print shapes

efficiently where a strictly subtractive process
would remove too much material. Finish machining
may be necessary for dimensional finish needs.

Programs like Generative Design can make light

weighted 3D-printed metal objects, yet retain
the necessary strength characteristics needed.
In this instance, milling may be needed just on
certain surfaces.

18 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

 CONCLUSION
It’s often difficult to find the time and the budget to increase productivity in the job shop. The key is not to
try to do everything at once. Rather, best-in-class job shops continually make incremental changes. This is
made possible by the fact that most improvements are not dependent on one another. This allows for lots of
flexibility when creating your productivity roadmap. Assess which solutions will have the greatest impact on
your organization and roll out the changes over a period of time.

In this fast-paced environment, it’s more important than ever to boost productivity. The good news is
becoming a best-in-class job shop is within your reach, one improvement at a time.

Get Started
Read to explore software solutions that can help boost productivity? Check out product demo videos to
learn about how various software solutions can help you become a best-in-class job shop.

EXPLORE SOFTWARE SOLUTIONS >

19 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP

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20 | THE DEFINITIVE GUIDE TO PRODUCTIVITY IN THE JOB SHOP